FRO­NIUS Acerios User manual

Operating
instructions
Acerios
42,0426,0326,EA 003-21032022
EN-US Operating instructions

Table of contents
Safety Instructions 6
Explanation of Safety Instructions 6
General 6
Intended Use 7
Environmental Conditions 7
Obligations of the Operating Company 7
Obligations of Personnel 7
Grid Connection 8
Personal Protection and Protection of Others 8
Data regarding Noise Emission Values 8
Danger from Toxic Gases and Vapors 9
Danger from Fire 9
Hazards from Grid Current and Process Current 10
Stray Currents 11
EMC Device Classifications 11
EMC Measures 11
EMF Measures 12
Particular Hazard Areas 12
Impaired Plasma Surface Treatment 13
Danger from Gas Cylinders 13
Danger due to Escaping Gas 13
Safety Measures at the Setup Location and During Transport 14
Safety Measures in Normal Operation 14
Maintenance and repair 15
Safety Inspection 15
Disposal 15
Safety symbols 16
Data backup 16
Copyright 16
General information 17
General 19
Device Concept 19
Operating Principle 19
Application Areas 20
System Configurations 20
Operating controls and connections 21
Control Panel 23
General 23
Safety 23
Control Panel 24
Shortcut Keys - Special Functions 27
General 27
Key Lock 27
Show Software Version, Runtime, and Coolant Flow 28
Connections, Switches, and Mechanical Components 29
Acerios Connections 29
Installation and Startup 31
Before installation and initial operation 33
Safety 33
Minimum Equipment 33
Intended Use 33
Setup regulations 33
Grid Connection 34
Installation 35
Safety 35
3
EN-US

General 35
Installation 35
Commissioning 37
Connecting the Gas Cylinder 37
Connecting the Plasma Torch 37
Plasma Surface Treatment 39
Overloaded Electrode 41
Overloaded Electrode 41
Description of operating modes 42
2-Step Mode 42
4-Step Mode 42
Plasma Surface Treatment 43
Safety 43
Process Parameters 43
Plasma Surface Treatment 44
Special Functions and Options 45
Arc Break Monitoring Function 45
Ignition Time-Out Function 45
Plasma Pulsing 45
Hold-Function 46
Job Mode 47
General 47
Abbreviations 47
Saving a Job 48
Job Retrieval 49
Copying/Overwriting a Job 50
Deleting a Job 52
Setup Settings 53
The Setup Menu 55
General 55
Accessing the Setup Menu 55
Accessing the 2nd Level Setup Menu 55
Adjusting Parameters 55
Parameters in the Setup Menu 56
Parameters in the 2nd Level Setup Menu 57
Exiting the 2nd Level Setup Menu 60
Exiting the Setup Menu 60
Displaying Plasma System Resistance r 61
General 61
Measuring Plasma System Resistance r 61
Displaying Plasma System Inductance L 62
General Information on Plasma System Inductance L 62
Displaying Plasma System Inductance L 62
The Gas Menu 63
General 63
Accessing the Gas Menu 63
Adjusting Parameters 63
Parameters in the Gas Menu 63
Exiting the Setup Menu 64
The Job Correction Menu 65
General 65
Accessing the Job Correction Menu 65
Adjusting Parameters 65
Correctable Parameters in the Job Correction Menu 65
Exiting the Job Correction Menu 67
Troubleshooting and Maintenance 69
Troubleshooting 71
General 71
4

Safety 71
Displayed Service Codes 71
Power Source Troubleshooting 75
Service, maintenance and disposal 77
General 77
Safety 77
At every start-up 77
Every 2 Months 77
Every 6 Months 78
Disposal 78
Appendix 79
Technical data 81
Special Voltage 81
Acerios 81
Explanation of Footnotes 81
5
EN-US

Safety Instructions
Explanation of
Safety Instruc-
tions
DANGER!
Indicates an immediate danger.
▶Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
▶Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
▶Minor injury or damage to property may result if appropriate precautions are
not taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
General The device has been manufactured using state-of-the-art technology and ac-
cording to recognized safety standards. If used incorrectly or misused, however,
it can cause
-serious or fatal injury to the operator or a third party,
-damage to the device and other material assets belonging to the operating
company,
-inefficient operation of the device.
All persons involved in the commissioning, operation, maintenance, and servicing
of the device must
-be suitably qualified,
-have knowledge of plasma surface treatment and
-have completely read and followed these Operating Instructions.
The Operating Instructions must always be kept to hand wherever the device is
being used. In addition to the Operating Instructions, all applicable local rules
and regulations regarding accident prevention and environmental protection
must also be followed.
All safety and danger notices on the device must
-be kept in a legible state
-not be damaged/marked
-not be removed
-not be covered, pasted, or painted over.
For the location of the safety and danger notices on the device, refer to the sec-
tion headed "General" in the Operating Instructions for the device.
Before switching on the device, remove any faults that could compromise safety.
Your personal safety is at stake!
6

Intended Use The device is to be used exclusively for its intended purpose.
The device is intended exclusively for the process specified on the rating plate.
Utilization for any other purpose, or in any other manner, shall be deemed to be
"not in accordance with the intended purpose". The manufacturer accepts no li-
ability for any damage resulting from improper use.
Intended use also means
-reading and adhering to all instructions in the Operating Instructions
-reading and adhering to all safety instructions and danger notices
-carrying out all the specified inspection and servicing work.
Never use the device for the following applications:
-Thawing pipes
-Charging batteries
-Starting motors
The device is designed for operation in industry and business. The manufacture
shall not be liable for any damage resulting from use in a living area.
The manufacturer shall also not be liable for faulty or incorrect work results.
Environmental
Conditions
Operation or storage of the device outside the stipulated area will be deemed as
not in accordance with the intended purpose. The manufacturer accepts no liab-
ility for any damage resulting from improper use.
Temperature range of the ambient air:
-During operation: -10°C to +40°C (14°F to 104°F)
-During transport and storage: -20°C to +55°C (-4°F to 131°F)
Relative humidity:
-Up to 50% at 40°C (104°F)
-Up to 90% at 20°C (68°F)
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)
Obligations of
the Operating
Company
The operating company must only allow persons to work with the device if they
-Are familiar with the basic occupational safety and accident prevention regu-
lations and are trained in handling the device
-Have read and understood these Operating Instructions, especially the sec-
tion "Safety Rules," and have confirmed this with their signature
-Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
All persons who are assigned to work with the device must do the following be-
fore beginning the work:
-Follow the basic regulations for occupational safety and accident prevention
-Read these Operating Instructions, especially the section "Safety Rules," and
confirm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage
can occur in one's absence.
7
EN-US

Grid Connection Devices with a high output can influence the energy quality of the grid due to
their current consumption.
This may affect a number of device types in terms of:
-connection restrictions
-criteria regarding maximum permissible grid impedance *)
-criteria regarding the minimum required short-circuit power *)
*) both at the interface with the public grid
See technical data
In this case, the operator or the person using the device should check whether or
not the device is allowed to be connected, where appropriate through discussion
with the power supply company.
IMPORTANT! Ensure secure grounding of the grid connection!
Personal Protec-
tion and Protec-
tion of Others
You are exposed to numerous hazards while handling the device, for example:
-Flying sparks and pieces of hot metal
-Arc radiation that poses a risk of injury to the eyes and skin
-Hazardous electromagnetic fields that pose a risk of death for individuals
with pacemakers
-Electrical risks from grid current and welding current
-Increased noise exposure
-Harmful fumes and gases
Wear suitable protective clothing when dealing with the device. The protective
clothing must have the following properties:
-Flame resistant
-Insulating and dry
-Covering the entire body and in good condition with no damage
-Safety helmet
-Cuffless pants
Protective clothing involves the following:
-Protecting the face and eyes from UV radiation, heat, and flying sparks with a
face guard featuring a regulation-compliant filter.
-Wearing regulation-compliant protective goggles with side protection behind
the face guard.
-Wearing rigid, wet-insulating footwear.
-Protecting hands with appropriate gloves (featuring electrical insulation and
thermal protection).
-Wearing ear protection to reduce noise exposure and protect against injury.
Keep persons, especially children, away during the operation of the devices and
during the plasma surface treatment process. However, if persons are in the vi-
cinity:
-Instruct them about all hazards (blinding hazard due to arcs, risk of injury
from flying sparks, fumes hazardous to health, noise exposure, possible haz-
ard due to grid current or process current, etc.),
-Provide suitable protective equipment, or
-Construct suitable protective walls and curtains.
Data regarding
Noise Emission
Values
The device produces a maximum noise level of <80 dB(A) (ref. 1pW) when idling
and in the cooling phase following operation in relation to the maximum permit-
ted operating point at standard loading in accordance with EN 60974-1.
8

A work station-specific emission value cannot be specified because this value de-
pends on the process and the environmental conditions. It depends on differing
parameters, such as the power range, the component geometry, the material, the
resonance properties of the workpiece, the work station environment, and many
other factors.
Danger from
Toxic Gases and
Vapors
The fumes produced during plasma surface treatment contain toxic gases and
vapors.
The fumes produced contain substances that may cause birth defects and can-
cer in some circumstances.
Use at-source extraction source and a room extraction system.
If possible, use integrated extraction devices.
The operator of the plasma system is obliged to maintain the values for the max-
imum allowable concentrations (MAC).
-Ensure that there is sufficient fresh air!
-Arrange the extraction capacity so that at least 3 times the gas used can be
extracted per plasma torch.
Keep your head out of the fumes and gases.
Take the following precautionary measures for fumes and harmful gases:
-Do not breathe them in
-Extract them from the work area using appropriate equipment.
Use breathing apparatus with air supply if there is insufficient ventilation.
When no work is taking place, close the valve of the gas cylinder or the main gas
supply.
If there is uncertainty as to whether the extraction capacity is sufficient, com-
pare the measured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the fumes are:
-The materials used for the workpiece
-Electrodes
-Coatings
-Cleaning agents, degreasers, and the like
-The type and amount of component contamination
Consult the corresponding material safety data sheets and manufacturer's in-
structions for the components listed above.
Keep flammable vapors (such as solvent vapors) out of the arc radiation range.
Danger from Fire Flying sparks can cause fires and explosions.
Never perform the plasma surface treatment near flammable materials.
Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the
arc or protected with a certified cover.
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through
small cracks and openings. Take appropriate measures to ensure that there is no
risk of injury or fire.
9
EN-US

Only ever perform the plasma surface treatment in areas at risk of fire and ex-
plosion, on sealed tanks, drums, or pipes if these have been prepared in accord-
ance with corresponding national and international standards.
Do not perform the plasma surface treatment on containers in which gases,
fuels, mineral oils, and the like are/were stored. Residues pose a risk of explosion.
Do not perform plasma surface treatments on materials or contamination which
could cause a fire when the plasma arc is operated.
Hazards from
Grid Current and
Process Current
An electric shock is life-threatening and may be deadly.
Do not touch voltage-carrying parts inside or outside the device.
Ensure suitable personal protection with dry temporary backing or cover with
sufficient insulation against the ground potential. The temporary backing or cov-
er must completely cover the entire area between the body and the ground po-
tential.
All cables and leads must be secured, undamaged, insulated, and adequately di-
mensioned. Replace loose connections and scorched, damaged, or inadequately
dimensioned cables and leads immediately.
Before every use, check power connections for secure fit by hand.
In the case of power cables with bayonet connectors, turn the power cable by at
least 180° around the longitudinal axis and pretension.
Do not wrap cables or leads around your body or parts of the body.
The electrode
-never immerse it in liquids to cool it
-never touch it when the power source is switched on.
The open circuit voltage of a device may double, for example, between two
voltage-carrying electrodes. Touching the potentials of both electrodes at the
same time may be life-threatening in some cases.
Have the grid and device supply lead regularly inspected by an electrician to en-
sure that the ground conductor is functioning properly.
Only operate the device on a grid with a ground conductor and a socket with a
ground conductor contact.
Operating the device on a grid without a ground conductor and on a socket
without a ground conductor contact is considered gross negligence. The manu-
facturer accepts no liability for any damage resulting from improper use.
Use suitable equipment to ensure that the workpiece is sufficiently grounded if
necessary.
Switch off unused devices.
Before working on the device, switch off the device and remove the mains plug.
Secure the device to prevent the mains plug from being connected and switched
on again by applying a clearly legible and understandable warning sign.
After opening the device:
-Discharge all electrically charged components
-Ensure that all components are disconnected from the power supply.
If work is needed on voltage-carrying parts, bring in a second person who will
switch off the main switch at the correct time.
10